Method for the automatic eneveloping of small items such as documents and device used to implement same

ABSTRACT

The invention relates to an automatic device which is used to envelope small items and which can be used to perform very-high-speed enveloping. The inventive device comprises a frame ( 11 ) having the following components mounted thereto, namely: a storage bin ( 12 ) containing a pile of stacked envelopes ( 15 ) which are disposed such that they can be removed one by one from the base of the bin, and a control drum ( 13 ) which is associated with a rotary cam ( 14 ). The aforementioned control drum ( 13 ) is arranged such as to move the envelopes ( 15 ) individually and successively from the storage bin ( 12 ) towards an area where a document is inserted therein and such as to open the envelope when the rotary cam ( 14 ) has unfolded the flap of same. The documents ( 30 ) to be inserted into the envelopes ( 15 ) are conveyed by way of cogs ( 32 ) which are solidly connected to a continuously-moving transport chain ( 31 ).

This application is a national stage completion of PCT/CH2004/000579filed Sep. 14, 2004 which claims priority from French Application SerialNo. 03/10961 filed Sep. 18, 2003.

TECHNICAL DOMAIN

The present invention concerns a method for automatically insertingsmall objects into envelopes, particularly documents or objects to betransmitted in envelopes using a mailing service, by utilizing a devicethat comprises a storage means and a means for successively feedingindividual envelopes, a means for moving the documents or objects to betransmitted toward the individual envelopes comprising a folded closingflap, and a means for introducing one of the documents or one of theobjects into one of the envelopes.

It also concerns the device implementing this method.

PRIOR ART

Devices of this type for inserting letters, publicity material, or thelike into envelopes for large scale distribution are already known inthe art. These devices are generally complicated in design and comprisea large number of moving mechanical parts to guide and feed theenvelopes on the one hand and the documents on the other hand toward thezone where the two delivery components meet, called the packaging zone.Since the paths taken by the envelopes and by the documents areseparate, whereas the packaging area is a common one, in currently useddevices the envelopes are usually first moved along a trajectory in thedirection opposite to that of the documents and then along a trajectoryidentical to that of the documents after the documents have beenintroduced inside the envelopes. This reversal of direction generallyrequires the use of a switching mechanism to separate the arrival anddeparture paths of the envelopes.

Such a design is complicated and it operates slowly, considerablyreducing the speed of the packaging operation. In practice, with thissystem each cycle must be completely finished before the next cycle canstart up, that is, one envelope must be filled with the documentsintended for it and evacuated from the packaging zone before the nextenvelope can be delivered to this same zone to receive its documents.The resulting reduced speed, in addition to the complicated equipmentdesign, makes the equipment difficult to maintain and subject tofrequent breakdowns.

U.S. Pat. No. 2,643,119A describes a packaging device comprising severalunits with a storage unit for obliquely arranged envelopes which areremoved one at a time using a rotary drum. An air blower is locatedbehind the zone where the envelopes stop in order to open them and allowthem to receive the letters or documents to be placed inside. However,this device has several drawbacks. The envelopes are removed while theyare closed and through gravitational force pass in groups from a firstplatform to a second platform where they are taken up by the drum. Thereis a considerable risk that several envelopes will be selectedsimultaneously, causing a jam. Furthermore, the envelopes, which aretransferred while closed, are not opened by the blower until the momentthey arrive at the stop. This sequence reduces speed and creates a highrisk that the envelopes will fail to open.

The objective of U.S. Pat. No. 3,423,900 A is to achieve a machine thatcan insert into an envelope several documents, cards, or letters thatare separately stored. The envelopes are transported by a rotary drumequipped with a mechanical gripping means and which comprises groovesfor the envelope flaps. The documents and the envelopes are driventowards a zone for filling the envelopes with the documents. Thismachine is completely mechanical and all the operations of themaintenance or gripping fingers are controlled by cams. This procedure,however, does not allow work to progress at a very high speed.

U.S. Pat. No. 4,649,691 A concerns an automatic envelope filling machinein which the envelopes are removed mechanically using claws attached toa rotary drum. The envelope is opened by blowers that raise the flapwhen it arrives in the position for receiving documents. It does notprovide any mechanical control to guaranty that the envelope iscorrectly opened.

U.S. Pat. No. 3,962,848A describes a device wherein envelopes stacked ina column are removed using friction from a rotary drum, opened by ablower, and transported on a conveyor. This system is based only onfriction and cannot work reliably at high speed.

The automatic envelope filling machine which is the subject of U.S.Patent No. 3,381,447 A comprises a first drum for removing an item fromstored instruction inserts or the like, and a second drum for removingenvelopes. The instruction inserts are fed towards a wheel with radialcavities through which the envelopes have been introduced previously,the cavities comprising opening means. Such a device is relatively slowbecause the envelopes and the documents introduced inside them must beinserted into and then withdrawn from the cavities in the rotatingwheel, which cannot be done continuously and thus requires time to stopthe wheel.

EXPLANATION OF THE INVENTION

The objective of the present invention is to eliminate the disadvantagesof these known devices by providing a simple, effective device that iseasy to maintain and is capable of automatically filling envelopes at avery high speed.

This goal is achieved by the method defined in the preamble andcharacterized in that the envelopes are stored in such a way that theflap of each individual envelope is located on the bottom of theenvelope and towards the front in the direction of removal, in that theflap is unfolded downward in the direction in which the envelope opens,in that the envelope flap is moved into contact with the control drum,in that each envelope is displaced individually and successively bypulling its flap placed against the exterior surface of the control drumtowards the zone for introducing the documents or objects, in that theenvelope is then opened and the document or the object is thenintroduced inside the previously opened envelope.

Advantageously, the envelope flap is unfolded by at least one stream ofair and flattened against the surface of the positioning drum by meansof radial suction produced inside the drum.

Preferably, the envelopes are detached from the positioning drum usingat least one scraper that is tangential relative to the drum surface.

It is possible to open each envelope using opening guides, and theenvelope can also be compressed laterally.

The device for implementing this method of automatically inserting smallobjects into envelopes, particularly documents or objects to be sent bya mailing service, is characterized in that the means for feeding theindividual envelopes consists of a control drum design to displace theenvelopes individually and successively from the storage means towardsthe zone for introduction of one of the documents or one of the objectsinto one of the individual envelopes, and in that the means forintroducing one of these documents or one of these objects into one ofthe envelopes comprises a means for unfolding the flap of the individualenvelope and opening this envelope.

According to a preferred embodiment, the control drum comprises at leastone peripheral zone that is perforated with openings and the openingsare connected to a suction device in an intermediate zone between thestorage means and the zone for introducing one of the documents into oneof the individual envelopes.

According to an advantageous embodiment, the openings are connected to apressurized air generating device in the zone for introducing one of thedocuments into one of the individual envelopes.

The control drum preferably comprises on at least a portion of itsperiphery a covering with a high coefficient of friction.

According to one advantageous embodiment, the peripheral covering on thecontrol drum extends over an angular section comprising from 25% to 75%of the periphery.

According to a particular embodiment, the peripheral coating on thecontrol drum comprises several parallel bands extending over an angularsection comprising from 25% to 75% of the periphery.

The means for opening the individual envelopes preferably comprises atleast one rotary cam designed to engage beneath the flap of eachindividual envelope in order to unfold it.

In order for one envelope to be taken up during each cycle thatcorresponds to one rotation by the control drum, the rotary cam isdriven synchronously with the drum.

According to a particularly advantageous design, the rotary cam isequipped with at least one organ that generates at least one stream ofair to assist in unfolding the flap of each individual envelope in orderto open it.

The rotary cam is preferably equipped with at least one projection toinitiate the unfolding of the flap of the individual envelope.

Preferably, the control drum and the rotary cam have the same diameterand are driven synchronously at the same speed and, on one portion oftheir circular trajectory, the rotary cam contacts the peripheralsurface of the control drum to drive one envelope from the storage meanstowards the introduction zone.

To detach the envelopes from the control drum, the device advantageouslycomprises at least one scraper which detaches the individual envelopefrom the control drum in the introduction zone.

Advantageously, the device comprises several scrapers parallel to eachother, the scrapers being located between the parallel bands of thecovering on the control drum.

To facilitate opening the envelope, the device may comprise lateraldeflectors for pushing together the lateral edges of the individualenvelopes to assist in opening them.

According to a first embodiment, the lateral deflectors comprise guiderollers.

According to a second embodiment, the lateral deflectors comprises guidesections.

According to a particular embodiment, the control drum comprises atleast two cylindrical sections that are separated by at least oneunattached ring.

SUMMARY DESCRIPTION OF THE DRAWINGS

The present invention and its features will be better understood fromthe description of its preferred embodiments, furnished by way ofnon-limiting examples, with reference to the attached drawings, wherein:

FIG. 1A is a partial perspective representing the principal elementsconstituting a first embodiment of the device according to theinvention;

FIG. 1B is an elevation of the device of FIG. 1A shown in a particularphase of operation;

FIG. 1C is an elevation of the device of FIG. 1A shown in anotherparticular phase of operation;

FIGS. 1D, 1E and 1F are enlarged partial views of certain portions ofthe device of FIG. 1A in particular positions corresponding tooperational phases of the device;

FIG. 1G is a detailed view showing one element of the device of FIG. 1A;

FIG. 1H shows one portion of the device of FIG. 1A during operation;

FIG. 1I is a plane view from the top of the device of FIG. 1A;

FIG. 1J is a perspective view from below showing the device of FIG. 1Aduring operation;

FIG. 2A is a partial perspective showing the principal elementsconstituting a second embodiment of the device according to theinvention; and

FIGS. 2B, 2C and 2D are enlarged partial views of certain portions ofthe device of FIG. 2A in particular positions corresponding tooperational phases of the device.

HOW TO ACHIEVE THE INVENTION

With reference to FIGS. 1A through 1J, device 10 consists principally ofa frame 11, shown schematically by a lateral support element, but whichmay comprise as shown in FIG. 1I two lateral support elements that areparallel and essentially identical, to which a storage bin 12 forenvelopes or packets is attached, the bin constituting the storage anddelivery means, a control drum 13, and at least one rotary cam 14.Storage bin 12 may contain a stack of superimposed envelopes 15 arrangedso they may be removed one at a time from the base of the bin. Thestorage bin is open at the base, allowing rotary cam 14 to accessenvelope 15 located at the lower part of the stack. Each envelope isarranged so its closing flap is folded down against the envelopesurface.

Cylindrical control drum 13 is attached to a rotary shaft 16 supportedby frame 11. It may be made of metal or synthetic material, for example,a carbon fiber based-material or the like. It comprises an exteriorcovering 17 consisting of a material with a high coefficient offriction, such as, for example, foam rubber or the like. This exteriorcovering 17 preferably extends along only one portion of the drumperiphery, for example, along an angular section ranging from 25% to 75%and preferably of the order of 50%. The covering advantageously takesthe form of several parallel bands 18 which may be three in number,separated by annular spaces 19. Drum 13 is perforated and in the areawith the covering, it comprises a plurality of openings 20 penetratingexterior covering 17. These openings communicate with the hollowinterior of control drum 13 and because of this they are connectedthrough a turning connection to a suction device (not shown) when thecontrol drum is in an intermediate zone between the storage means andthe zone for introduction of one of the documents into one of theindividual envelopes 15.

When the control drum 13 is located in the zone for introduction of oneof the documents into one of the individual envelopes, the openings 20are connected through a turning connection to a pressurized air deliverydevice which detaches the envelope from the control drum.

Rotary cams 14, which number three in the embodiment shown, are attachedto a shaft 21 supported by the frame 11 and are driven in synchronousrotation with the control drum 13.

The mechanism which drives and connects the two shafts 16 and 21 isshown schematically by a circle A. The rotary cams 14 comprise aprojection 22 which initiates the unfolding of the flap of eachindividual envelope during each operational cycle by the device. Thisprojection 22 is equipped with at least one nozzle 23 producing a streamof air 24 (see FIG. 1D) designed to contribute to the unfolding of eachindividual envelope flap in order to open the envelope. This nozzle 23is supplied with compressed air through a turning connection (not shown)attached to shaft 21.

Device 10 further comprises at least one scraper 25 designed to detachthe individual envelope from the control drum 13 in the introductionzone. In the exemplary embodiment described, it comprises two parallelscrapers 25 attached to an axle 26 supported by frame 11. These scrapersconsist of a thin plate slightly curved at its free end that contactsthe peripheral surface of control drum 13.

In the example shown, control drum 13 comprises, on one portion ofannular spaces 19, bearing supports 27 or roller supports 28 that rotatefreely, which are level with the peripheral drum surface and over whichscrapers 25 can slide without engaging. The function of these unattachedbearings or rollers 28 is to facilitate detachment of the individualenvelopes from the drum in the zone for introduction of documents orobjects into the envelopes.

Parallel bands 18 of exterior coating 17 on control drum 13 form anextra layer and define two hollow annular spaces 19. The unattached endsof the plates constituting scrapers 25 contact the peripheral drumsurface in the two hollow annular spaces 19. The number of these hollowannular spaces depends upon the number of parallel bands 18 of exteriorcovering. This number is not critical and there should be a minimum oftwo.

In the zone for introduction of one of the documents into one of theindividual envelopes 15, the device is equipped with two opening guides29 each comprising two branches 29 a and 29 b, converging at oneextremity to define a projection for opening the envelopes. Documents 30to be introduced in the individual envelopes are delivered in knownmanner along rails or some type of support and guide surface 31, forexample, a conveyor belt, and are driven by cogs 32 integral with thisendless conveyor belt. The filled envelopes are then taken up by arecovery cam 33 rotating on shaft 34, which rotates synchronously withcontrol drum 13. The synchronous driving of shaft 16 for drum 13 andshaft 34 for recovery cam 33 is shown schematically by circle 35.

As shown more particularly by FIG. 11, device 10 is further equippedwith two lateral deflectors 36 which push the lateral edges of theenvelopes together to help open them. These deflectors consist of guideprofiles, but they may also be equipped with rollers to reduce thefriction of contact with the envelope.

During one operating cycle the device operates according to theprinciple of the invention wherein the envelopes are stored in such away that the flap of each individual envelope is on the bottom of theenvelope and towards the front in the direction of removal, the flap isunfolded downwards in the direction in which the envelope opens, theenvelope flap is moved into contact with the surface of the controldrum, the envelopes are individually and successively displaced bypulling the flaps placed against the exterior surface of the controldrum towards the zone for introduction of one of the documents or theenvelopes, the envelopes are then opened and the documents or theobjects are introduced inside the previously opened envelopes.

Consequently, to effect this series of operations, the elementscomprising device 10 operate as follows:

Rotary cams 14 turn counterclockwise so that projections 22 move closerto the flap of the lower envelope in stack of envelopes 15.

Nozzles 23 begin to act and emit a stream of air 24 (see FIG. 1D) thatinitiates unfolding of the envelope flap.

Projection 22 on rotary cam 14 comes into contact with the flap andcompletes the unfolding.

The unfolded flap comes into contact with control drum 13 in the zonewhich has exterior covering 17.

Suction passing through holes 20 of the drum then flattens the unfoldedflap against control drum 13 and the entire envelope is then sandwichedbetween the drum and rotary cams 14.

The envelope arrives at the document introduction zone and lateraldeflectors 36 press in opposing directions against the lateral envelopeedges to initiate opening.

Scrapers 25 detach the flap and then the entire envelope from controldrum 13. The scrapers are assisted in this function by compressed airblown through openings 20 formed in the peripheral wall of the drum andexterior covering 17.

The envelope is speared by opening guides 29 which complete the envelopeopening by engaging their two branches 29 a and 29 b in the envelopeopening and positioning it at the stop so it will be ready to receivedocuments 30.

The documents 30 arrive and engage with the open envelope.

The envelope is then driven by cogs 32 of conveyor belt 31 which has fedthe documents.

The envelope containing documents 30 is evacuated through the action ofuptake cam 33 which contacts unattached bearings or rollers 28 oncontrol drum 13. The bearings or rollers 28 rotate freely so as not toimpede the envelope evacuation process activated by uptake cam 33.

During these later phases when the envelope is detached from controldrum 13, the first phases of the next cycle may be already underway,allowing work to take place in condensed time and reducing the effectiveduration of a cycle, thereby increasing the speed of the device.

In the example shown in FIGS. 2A through 2D all the components of device50 are identical to those of device 10 described above, except controldrum 53 differs in design and function from control drum 13.

With reference to the drawings, the device 50 principally comprises aframe 51 shown schematically by a lateral support element to which thereare attached a bin 52 for storing envelopes or packets, the binconstituting the storage and conveyance means, a control drum 53 and atleast one rotary cam 54. Storage bin 52 may contain for example a stackof superimposed envelopes 55 arranged so they may be removed one by onefrom the base of the bin. The base of the storage bin is open, allowingrotary cam 54 to access envelope 55 located at the lower portion of thestack. Each envelope is positioned so that its closing flap is foldedagainst the body of the envelope.

Cylindrical control drum 53 is attached to a rotary shaft 56 supportedby frame 51. Like drum 13, it has an exterior covering 57 consisting ofa material with a high coefficient of friction which preferably extendsalong a portion of its periphery.

The coating 57 advantageously takes the form of several parallel bands58, which may be three in number, separated by annular spaces. The drumis perforated and in the covered zone it comprises a plurality ofopenings 60 penetrating the exterior covering. These openingscommunicate with the hollow interior of control drum 53 and for thisreason they are connected by a turning connection to a suction device(not shown) when the control drum is in an intermediate zone between thestorage means 52 and the zone for introducing documents into one of theindividual envelopes.

Rotary cams 54, which are three in number in the embodiment shown, areattached to a shaft 61 supported by the frame 51 and driven to rotatesynchronously with the control drum 53. The rotary cams 54 comprise aprojection 62 to initiate the unfolding of each individual envelopeduring each cycle of operation by the device. The projection 62 isequipped with at least one nozzle 63 producing a stream of air 64 (seeFIG. 2D) which assists in unfolding the flap of each individual envelopein order to open the envelope.

Device 50 further comprises at least one scraper 65 for detaching theindividual envelope from the control drum 53 in the introduction zone.

In the zone for introduction of one of the documents into one of theindividual envelopes, the device is equipped with two opening guides 69each comprising two branches 69 a and 69 b that reconnect at one oftheir extremities to define an envelope opening projection. Thedocuments to be introduced into the individual envelopes are moved inknown manner along rails or any sort of support and guide surface 71,for example a conveyor belt, and are driven by cogs 72 integral with theendless conveyor belt. The filled envelopes are then taken by an uptakecam 73 rotating on shaft 74 which rotates synchronously with controldrum 53.

As FIGS. 2B and 2C show more specifically, control drum 53 is composedof cylindrical segments 80, which may be three in number, each with acovering 57 along a portion of its periphery and which are separated byunattached rings 81 which are formed in the example shown of a ballbearing with a cage 82 composed of an interior ring 83 and an exteriorring 84 enclosing bearings 85. In this way cylindrical segments 80 andunattached rings 81 can turn independently. The envelopes are in contactwith covering 57 along a portion of their trajectory and then, havingreceived the documents, they are in contact with unattached rings 81, ormore specifically, they are sandwiched between these rings and uptakecams 73.

1-24. (canceled)
 25. A method for automatically inserting small itemsinto envelopes, particularly documents or objects to be transmitted inthe envelopes using a mailing service by means of a device comprising ameans for storage and for successively feeding the envelopes, a meansfor moving the documents or objects to be transmitted toward theenvelopes with a folded closing flap, and a means for introducing one ofthe documents or one of the objects to be transmitted into one of theenvelopes, the method comprising the steps of: storing the envelopes insuch a way that the flap of each of the envelopes is located at a bottomof the envelope and towards a front, in a direction of removal;unfolding the flap downwards in a direction of an envelope opening;moving the envelope flap into contact with a surface of a control drum;displacing each of the envelope, individually and successively, bypulling the flap placed against an exterior surface of the control drumtowards a zone for introduction of one of the documents or one of theobjects to be transmitted; and opening the envelope then, andintroducing the document or the object to be transmitted into the openedenvelope.
 26. The method according to claim 25, further comprising thestep of unfolding the envelope flap by generating at least one stream ofair.
 27. The method according to claim 25, further comprising the stepof placing the envelope against the surface of the control drum byradial suction produced inside the control drum.
 28. The methodaccording to claim 25, further comprising the step of detaching theenvelopes from the control drum by means of at least one scraper that istangential in relation to the surface of the drum.
 29. The methodaccording to claim 25, further comprising the step of opening eachenvelope by means of opening guides.
 30. The method according to claim29, further comprising the step of compressing the enveloped laterally.31. The device (10, 50) for implementing the method of automaticallyinserting small items into the envelopes, particularly documents orobjects to be transmitted by the mailing service, according to claim 25,the device comprising the storage means (12, 52) and the means forsuccessively feeding the individual envelopes (15), a means for feedingthe documents or objects to be transmitted toward the individualenvelopes with a folded closing flap, and the means for introducing oneof the documents or one of the objects to be transmitted inside one ofthe envelopes, the means of feeding the individual envelopes comprisesthe control drum (13, 53) which displaces the envelopes (15)individually and successively from the storage means (12, 52) towardsthe zone for introducing the one of the documents or the one of theobjects to be transmitted into one of the individual envelopes, and inthat the means for introducing one of the documents or one of theobjects into one of the envelopes comprises a means (14, 22, 23; 54, 52,63) for unfolding the flap of the individual envelope and opening theenvelope.
 32. The device according to claim 31, wherein the control drum(13, 53) comprises at least one peripheral zone (17, 57) perforated withopenings (20, 60), the openings are connected to a suction device in anintermediate zone between the storage means and the zone forintroduction of one of the documents into one of the individualenvelopes.
 33. The device according to claim 32, wherein the openings(20, 60) are connected to a pressurized air generating device in thezone for introduction of one of the documents into one of the individualenvelopes.
 34. The device according to claim 31, wherein the controldrum (13, 53) comprises on at least a portion of its periphery, acovering (17, 57) with a high coefficient of friction.
 35. The deviceaccording to claim 34, wherein the peripheral covering (17, 57) on thecontrol drum (13, 53) extends over an angular section comprising between25% and 75% of the periphery.
 36. The device according to claim 34,wherein the peripheral covering (17, 57) on the control drum comprisesseveral parallel bands (18, 58) extending over an angular sectioncomprising at least between 25% to 75% of the periphery.
 37. The deviceaccording to claim 31, wherein the means for opening the individualenvelopes comprises at least one rotary cam (14, 54) which engages belowthe flap of each individual envelope in order to unfold the flap. 38.The device according to claim 37, wherein the rotary cam (14, 54) isdriven synchronously with the control drum.
 39. The device according toclaim 37, wherein the rotary cam (14, 54) is provided with at least oneorgan (23, 63) generating at least one stream of air (24, 64) to assistwith unfolding the flap of each individual envelope in order to open theenvelope. 40 The device according to claim 37, characterized in that therotary cam (14, 54) is provided with at least one projection (22, 62)for initiating unfolding of the flap of each individual envelope. 41.The device according to claim 31, wherein the control drum (13, 53) andthe rotary cam (14, 54) have a same diameter and are drivensynchronously at a same speed and along a portion of a circulartrajectory of the control drum and the rotary cam, the rotary cam (14,54) is in contact with a peripheral surface of the control drum (23, 53)to drive the envelope from the storage means (12, 52) towards theintroduction zone.
 42. The device according to claim 31, wherein thedevice comprises at least one scraper (25, 65) for detaching theindividual envelope from the control drum (13, 53) in the introductionzone.
 43. The device according to claim 31, wherein the device comprisesseveral scrapers (25, 65) arranged in parallel, the scrapers beinglocated between parallel bands (18, 58) of a peripheral covering (17,67) on the control drum.
 44. The device according to claim 31, whereinthe device comprises lateral deflectors (36) to push together lateraledges of the individual envelopes and assist in opening the envelopes.45. The device according to claim 44, wherein the lateral deflectors(36) comprise guide rollers.
 46. The device according to claim 44,wherein the lateral deflectors (36) comprise guide profiles.
 47. Thedevice according to claim 31, wherein the control drum (53) comprises atleast two cylindrical segments (80) separated by at least one unattachedring (81).
 48. The device according to claim 47, wherein the unattachedring (81) is formed of a roller.